What Is LEV Testing? A Practical Guide for UK Workplaces

In industrial environments, air quality should never be treated as a secondary consideration. Dust, fumes, vapours, mists and other airborne particles can affect employee health, compromise equipment, impair process cleanliness and create compliance risks. Different types of extraction systems are designed for different working environments and applications, helping businesses control contaminants, maintain clean air and meet safety standards.

In the UK, this is closely linked to the Health and Safety at Work etc. Act 1974, COSHH and, in certain applications, DSEAR. Choosing the right extraction system is therefore not only a technical decision, but also an operational and legal one. In many cases, effective dust extraction and fume extraction are essential to creating a safer working environment.

For many companies, the question is not whether to invest in extraction systems, but which system is most suitable for their process. The answer depends on the contaminant generated, the volume of material in the air, the layout of the facility, the filtration efficiency required and how the contaminant should be captured. Well-designed extraction systems help protect employees from harmful substances while supporting reliable day-to-day performance.

Key Takeaways

• Extraction systems are essential in industrial environments for controlling dust, fumes, vapours and other contaminants at the point of generation, helping to improve air quality, protect workers and support compliance with UK health and safety requirements.

• The main types of extraction systems include dust extraction systems, fume extraction systems, LEV systems, vacuum extractors, power tool extractor units and air filters, with the right choice depending on the contaminant, the process and the level of filtration efficiency required.

• In the UK, an effective system depends not only on correct installation, but also on ongoing maintenance, LEV testing and consistent performance in line with COSHH, current GB workplace exposure limits and, where applicable, DSEAR.

Why Extraction Systems Are So Important in Industrial Environments

In any industry, the problem is rarely limited to visible dust. Often, the greater risk comes from fine dust, very fine dust fractions and other respirable contaminants that remain in the air for longer and reach workers’ breathing zones. Exposure to airborne contaminants can contribute to health problems, respiratory issues and longer-term occupational risk.

This is precisely why the HSE treats local exhaust ventilation (LEV) as a key means of controlling workplace fume and dust extraction at the point of generation.

The impact also varies depending on the process. In carpentry and joinery, for example, wood dust remains a serious health and safety concern, and the HSE provides specific guidance on controlling this risk through LEV and good capture practices. Effective control is essential not only to manage the dust generated during woodworking, but also to reduce exposure to harmful substances contained within airborne dust.

In welding, welding fumes are subject to COSHH, and engineering controls, including fume extraction, are essential for reducing occupational exposure. In food sectors, organic dusts such as flour can also create a fire or explosion risk, bringing DSEAR to the forefront of technical decision-making.

In addition to protecting health, there are sound operational reasons to invest in well-designed dust extraction systems and fume extraction systems. The build-up of contaminants can accelerate wear, affect surfaces, impair finishes, increase cleaning requirements and reduce process reliability.

At A1, extraction systems are designed to support productivity, compliance and worker protection in workshops, manufacturing plants and processing areas where air quality directly affects performance and operational continuity.

What are the main types of extraction systems used in industrial workplaces?

When discussing types of extraction systems, it is helpful to distinguish them by practical function rather than by commercial name. In industrial settings, the most common systems include dust extraction systems, fume extraction systems, vacuum extraction units, dedicated solutions for power tools, mist systems and ambient air filters.

In many cases, these systems operate on the same basic principle: capturing contaminants at source, transporting them through controlled airflow, and removing them through an appropriate filtration system. The right choice depends on the process, the contaminant and the level of filtration efficiency required.

Dust Extraction Systems

Dust extraction systems are specifically designed to remove dust particles and particulate matter generated by cutting, sanding, grinding, powder handling, wood processing, working with composites, stone, food ingredients and a wide range of other industrial operations. Choosing the right dust extraction system is important for effective collection, suitable filtration and compliance with relevant safety standards, particularly where significant volumes of dust are generated.

These systems typically combine local capture, ductwork, a fan or extractor, and a filter unit to collect material before it spreads throughout the working environment. A1 provides solutions with capture hoods, ductwork, extraction fans and dust collectors to remove dust, shavings and airborne contaminants in industries such as woodworking, metal fabrication and automotive repair.

The effectiveness of any such system depends less on the dust extractor label and more on how well it matches the actual contaminant. Coarse dust, sanding dust, wood dust and very fine particles all behave differently and require different collection and filtration characteristics. In some applications, dust extractors may also need to meet L class, M class or H class requirements, depending on the hazard level of the material being handled.

In the case of wood dust, risk control requires specific measures and appropriate guidance for LEV users, reinforcing the importance of not treating all dusts in the same way.

Fume Extraction Systems

Fume extraction systems are used when the main concern is not larger solid particles, but harmful fumes, vapours, gases or fine aerosols generated by processes such as welding, solvent use, heated materials, process chemicals, and certain laboratory or finishing operations. These systems are specifically designed to control airborne contaminants and harmful substances before they spread through the working environment.

In such cases, the system needs to capture the contaminant as close as possible to the point of emission, before it enters the operator’s breathing zone. In the UK, this is particularly important in welding. Welding fume is covered by COSHH and can cause lung disease, and for indoor work, the use of LEV to remove fume at source is a central part of effective control.

The HSE states that exposure to all welding fumes, including mild steel welding fumes, can cause lung cancer, which makes any approach based solely on general ventilation inadequate.

LEV Systems

Although many people treat LEV as if it were a separate system, in practice local exhaust ventilation is the technical basis behind many industrial extraction systems. The aim is always the same: to remove hazardous airborne contaminants directly at source before they disperse into the workplace.

This can be achieved through fixed hoods, articulated arms, booths, machine-integrated capture, fume cupboards, or centralised extraction systems connected to multiple capture points. In each case, the principle remains the same: capture contaminants at source, move them through controlled airflow and ducting, and remove them through an appropriate filtration unit.

That is why, when choosing between different types of systems, the most useful question is not simply ‘which extractor to buy?’, but ‘how will this system capture the contaminant in the actual process?’. LEV must be properly commissioned and tested to ensure adequate protection. At A1, the systems we design are engineered to meet or exceed COSHH regulations, with a focus on reliable performance and a safe working environment.

Vacuum Extractors and Power Tool Extractor Units

Vacuum extractors and power tool extractor units are generally best suited for localised tasks, mobile operations, maintenance, finishing and portable equipment. Rather than a larger extraction network, these units work well when the contaminant needs to be collected directly at the tool, at smaller generation points or for intermittent tasks.

In many workshops and industrial workplaces, this is useful for sanding dust, controlled cleaning, and small operations where a central system is not the most efficient solution. When these units are used on particularly hazardous materials, the class of equipment and the filter used become even more important.

Official guidance requires that the choice of equipment be aligned with the type of hazardous substance present and the level of exposure that needs to be controlled. In parallel, the current GB workplace exposure limits are listed in EH40 and are legally binding under COSHH, which directly influences the expected performance of the system.

Systems For Mist, Vapours And Specialised Contaminants

Not all industrial contaminants appear as dry dust. In machining, surface treatment, certain chemical processes and complex production environments, oil mist, coolant mist, odours, vapours and mixtures of contaminants can arise that require a more specific filtration system.

In such cases, the design of the system, the filter media and proper maintenance make a huge difference to the actual efficiency of the control. A1 works with customised systems to capture grime, odours and airborne contaminants, which reinforces the need to design the solution according to the process, and not just the general category of equipment.

Air Filters and Complementary Air Cleaning

Air filters and ambient air cleaning systems can be very useful, but they should not replace source capture when there is significant exposure. Their most appropriate role is usually complementary, such as reducing residual particles, improving clean air in large areas, and helping to control the build-up of airborne dust that has escaped from the main process. A1 understands the importance of choosing the right filter and maintaining the system to preserve the durability and efficiency of filtration.

How to Choose the Right System For Each Application

The best choice depends, first and foremost, on the contaminant. If the process generates dust from cutting, grinding, powder transfer or wood dust, the focus is usually on dust extraction with effective collection and filters suited to the material’s particle size. Where combustible or higher-risk dusts are involved, the system design may also need to account for specific safety requirements.

If the process generates fumes, vapours or gases, the system needs to prioritise fume extraction close to the source, often with a hood or capture arm designed around how the work is actually carried out. If there is a mixture of contaminants, the solution may require multiple stages of filtration or even hybrid systems.

It is also essential to consider airflow, capture position, layout, maintenance access, inlet sizes, frequency of use and the destination of the collected contaminant. A powerful extractor alone is not enough if capture is poorly positioned or if the filtration system does not match the nature of the material.

In its HSG258 guidance, the HSE presents LEV as a matter of decision, design, commissioning and testing, rather than a simple equipment purchase. In some sectors, there are additional criteria. In woodworking, the control of wood dust is a health risk issue in its own right. In welding, capture at source is central.

In food processing, food dusts may fall within the scope of DSEAR and require measures to control ignition sources and limit the effects of an incident. In bakeries, for example, flour dust can cause asthma and has a defined WEL, reinforcing the importance of dust extraction and good working practices to reduce exposure.

UK Compliance, Maintenance and Testing

In the United Kingdom, extraction systems must be designed within a clear compliance framework. The Health and Safety at Work etc. Act 1974 provides the foundation for protecting the health, safety and welfare of people at work. COSHH requires exposure to substances hazardous to health to be prevented or adequately controlled.

Where there is a fire or explosion risk linked to dangerous substances or combustible dusts, DSEAR adds specific duties relating to risk assessment, control measures, area classification and the prevention of ignition sources. In practice, this means system performance has to be maintained, not simply installed.

Employers must keep LEV in efficient working order, arrange thorough examination and testing at least every 14 months, and retain records for at least five years. That examination must confirm that the system continues to operate as intended and must be carried out by a competent person with the necessary knowledge, skills and experience. Ongoing LEV testing is essential for maintaining legal compliance, safety and reliable performance over time.

This is an area where many companies fall short. They invest in the system itself but do not apply the same level of attention to performance verification, maintenance and documentation afterwards. A1 supports clients with design, installation, maintenance and related system support services, which reflects the correct lifecycle approach to industrial extraction. Reliable performance depends as much on initial design as it does on maintenance, suitable filters and proper documentation.

Why Choose A1 Extraction Systems

When a company is looking for a partner for dust extraction systems or fume extraction systems, the most important factor is not simply the equipment itself, but the ability to turn a process problem into a genuinely suitable technical solution.

That is where A1 Extraction Systems adds value. The company provides customised extraction solutions for different industries, with systems designed to capture harmful particles, fumes and airborne pollutants at source while supporting COSHH compliance and effective long-term performance. Support is available across design, installation, maintenance and component selection.

Another important differentiator is A1’s consultative approach and ongoing support. The focus is not limited to initial installation, but extends to filters, replacements, technical support and maintenance over time. In extraction systems, this matters because system efficiency depends not only on original design, but also on filter compatibility, correct inspection and consistent performance.

For companies in the UK, that makes a practical difference. A well-specified system helps protect workers, reduce dust exposure, improve air quality, support legal requirements and create a safer working environment without adding unnecessary complexity to operations. It is this balance of safety, reliability and process suitability that makes a LEV supplier genuinely valuable.

Summary

The different types of extraction systems used in industrial workplaces are not there to satisfy a formality, but to control real risks. Dust extraction systems, fume extraction systems, LEV, vacuum extractors, power tool extractor units and air filters all have distinct roles, and each works best when matched to the right contaminant, process and layout.

In the UK, that choice must take into account not only air quality and productivity, but also COSHH, current GB WELs, ongoing maintenance, regular LEV testing and, where applicable, DSEAR. In other words, the best system is one that captures contaminants at source, maintains consistent filtration efficiency and continues to provide effective protection after installation.

Frequently Asked Questions